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HIGH PERFORMANCE

LUBRICANTS THAT
INCREASE UPTIME
AND PROLONG
THE LIFE OF WIND
TURBINES
CASTROL'S LIQUID ENGINEERS
HELP MEET THE CHALLENGES OF
THE WIND ENERGY INDUSTRY
LUBRICANT TECHNOLOGY PLAYS A VITAL ROLE IN UNIQUE CHALLENGES
KEEPING TODAY’S WIND TURBINES RUNNING OF THE WIND TURBINE
RELIABLY AND EFFICIENTLY. AFTERMARKET
Castrol has more than 30 years’ experience of supporting the wind energy industry with ENVIRONMENTAL CHALLENGES
world-class lubricants and product support services. We supply lubricants to thousands ■ Lubrication points are subject to dirt,
of wind turbines. Our parent company, BP, is one of the largest wind park owners in dust, water, high turbulence and
the U.S. with a gross generating capacity of around 2,600 MW – enough electricity extreme temperatures
to power over 775,000 average American homes. From this platform we can evaluate
the effectiveness of our products and services which are geared towards meeting the ■ They can be hundreds of feet in the air
demands of modern technology. ■ Access to offshore installations can be
Based on our own experience, and from working closely with Operations and hindered by a logistical factors, including
Maintenance managers, we understand the importance of increasing the efficiency of high seas
assets, maximising uptime and reducing downtime. Given the extreme challenges that
wind turbines face, the right lubrication choices can help extend wind turbine uptime OPERATIONAL CHALLENGES
and keep equipment performing effectively throughout its life. ■ Turbines need to run intermittently and
at varying speeds
■ They are subject to a very wide range of
temperatures – from -40ºC to >50ºC
■ High levels of vibration put pressure on
moving parts

COMMERCIAL CHALLENGES
■ Pricing competition from conventional
energy sources
■ Balancing income from equipment with
prolonging its service life
■ Greater output demand increases the
loading on bearings, drives and
gear boxes
OUR SOLUTIONS PROVEN PRODUCTS AND EXPERTISE
SUPPORTED BY PERFORMANCE YOU CAN TRUST
INNOVATION AND
Castrol’s solutions incorporate innovative
APPROVED BY OEMS lubricant technology to provide a high level
Castrol’s global reach gives you access to
our network of sales, engineering, research
of performance and protection. As well as and manufacturing capabilities, wherever
Formulated to help address the challenges using our own specialised testing facilities you operate. Our global sales and distributor
of the wind energy industry, our high to test our products’ effectiveness under network has an extensive knowledge of
performance gear oils, bearing lubricants, different operating conditions, we submit Castrol products and is on hand to support
hydraulic fluids and greases are supported our technologies to rigorous independent your wind farm operations and maintenance
by services to monitor lubricant quality comparison with competitor products. needs. A network of specialist service
and performance. companies can also support you during oil
In our laboratory tests, use of Castrol's gear
change procedures with Castrol products,
From our work with OEMs, wind energy oils like Optigear Synthetic X and Optigear
in line with the requirements of the wind
farm owners, turbine operators and service Synthetic CT has shown the following
turbine OEMs.
providers, we understand the need for advantages among others when compared
to other leading gear oils on the market: 1
Please refer to the Castrol Global website link or consult
products that deliver advantages in the
your Castrol representative who can share the various
field – not just in the lab. The wide range of
■ Significantly less micropitting global OEM approvals and endorsements
OEM approvals gives wind farm owners and
operators assurance of their suitability for ■ Lower weight loss on rollers (up to 50%)
any fleet1.
■ A lower friction coefficient
These qualities help prevent problems
caused by reduced gear tooth accuracy,
fatigue and failure associated with
micropitting and friction. As a result, using
Castrol’s gear oils help maximise an asset’s
return on investment by improving the
reliability of gearboxes, consuming less
power and protecting components from
damage. All of which helps lower the cost of
maintenance and repairs.
KEY LUBRICATION POINTS
OF A WIND TURBINE

5 1 4
2
6
5
7
3
1. MAIN BEARING
Castrol Spheerol LC 2
Castrol Optigear Synthetic X 320
Castrol Optitemp SW1
2. PITCH ADJUSTMENT
Castrol Optitemp SW1
Castrol Spheerol LC 2
3. YAW BEARING
Castrol Tribol 1350 – 2.5 PD
Castrol Optitemp SW1
4. HYDRAULIC SYSTEMS
Castrol Hyspin AWH-M 32
Castrol Hyspin HVI
Castrol Brayco 717
5. MAIN GEAR AND AUXILIARY GEAR DRIVES
Castrol Optigear Synthetic X 320
Castrol Optigear Synthetic CT 320
Castrol Optigear Synthetic A 320
Castrol Optigear MX 320 & MX 460
6. GENERATOR BEARING
Castrol Longtime PD 2
7. YAW OPEN GEAR
Castrol Tribol 1350 – 2.5 PD
Castrol Molub-Alloy 936 SF
CASTROL HIGH
PERFORMANCE GEAR
OILS ENGINEERED
FOR WIND ENERGY
GENERATION
Bearings, drives and gearboxes rank as the highest cause of costly downtime,
and these are the areas which are subject to increased loading in heavier duty
cycles. Gear oils account for almost 80 to 85% of the lubricants used in wind
farms, and Castrol has developed two high-performance gear oils to meet
the demands on wind turbine gearboxes: Optigear Synthetic X and Optigear
Synthetic CT.

CASTROL OPTIGEAR SYNTHETIC X


Castrol’s Liquid Engineers have developed this pioneering technology to
protect and enhance the performance of wind turbine gearboxes. Based on
synthetic hydrocarbons, Optigear Synthetic X contains surface improvement
additives which equalize surface roughness without creating damaging
abrasion, which may cause gearbox failure. The technology, supported by
OEM approvals, helps to prolong equipment life and protect against
future damage.

CASTROL OPTIGEAR SYNTHETIC CT


Castrol Optigear Synthetic CT has been formulated to meet major OEM
specifications for wind turbine gearboxes. Its combination of an advanced
additive system, high performance base fluid and ester-free formulation offers
gears maximum protection against corrosion, wear and shock loading. Its
excellent thermal and oxidative stability deliver reliable operation especially
where changes in temperature are experienced, as well as an extended
operating life compared to lubricants based on mineral oil.

GLOBAL RELIABILITY
As a global company, the benefits of Castrol’s products, services, technical teams and
distributor support are available wherever your wind farms need them.
Our commitment to supporting wind energy company’s efficiency program extends
to the investment we have made in both production processes proven by automatic
in-line particle counters in the filling line and packaging to help ensure that cleanliness
standards are maintained throughout supply and delivery.
USED OIL ANALYSIS FOR
PROACTIVE MONITORING
Any wind turbine equipment failure impacts production, availability and overall cost efficiency. A joint working
pro-active maintenance regime from Castrol can help you reduce gearbox failures by giving you insight into the
performance of your wind turbine equipment.

BENEFITS FOR YOU


■ Comprehensive joint monitoring plans help increase machinery availability and reliability
■ Testing to monitor oil and machine condition improves oil change frequency
■ Regular analysis helps identify trends which may indicate potential future problems
■ Results can be trended and represented graphically for easier reference
■ Trending specific parameters gives a good overview of system and/or machine performance
■ Technical recommendations can be made when analysis results are outside agreed limits
■ Helps improve equipment maintenance plans
■ Helps avoid unnecessary system changeovers and machinery failures
■ Reporting information (current and historic) enables performance tracking and monitoring
Please contact your Castrol representative for more information about the value that Castrol Used Oil
Analysis can deliver.

THE CASTROL OFFER


Our post warranty offer for customers will help to reduce downtime, increase overall
efficiency and maximise your return on asset investment through a combination of our
Products & Services offer:

GLOBAL PRODUCTS AND OEM APPROVALS GLOBAL LOGISTICS SUPPORT


Wide range of OEM approvals and Global reach and logistics support
endorsements* for our products
EXPERT KNOWLEDGE
USED OIL ANALYSIS PROGRAMS High quality pre filtered products from
Used Oil Analysis Program (UOA) to help our manufacturing plants*
build data transparency
CAPABILITY BUILDING PROGRAMS
FLUSHING PROCEDURE GUIDANCE Support through conducting joint programs
AND SUPPORT which will further strengthen existing teams'
Easy switch of gear oils with capabilities through our Global O&M best
flushing guidance practice sharing.

FILTER ANALYSIS SERVICE Please speak to your Castrol representative


*

Filter analysis service to analyse, understand who can share the updates with you.
wear particles and ensure proactive
maintenance for the specific gearbox
components to help reduce downtime
Further information about Castrol’s range of products and services
is available on the Castrol website and the Lubricant Oracle.
Visit www.castrol.com/windenergy

The information and recommendations contained herein are based upon laboratory research,
experience in the field and/or state-of-the-art procedures, and are believed to be accurate and reliable.
Castrol However, they are provided as information only and in no way modify, amend, enlarge, or create
Technology Centre any specification or warranty, and all warranties, express or implied, including without limitation the
Whitchurch Hill warranties of merchantability and fitness for a particular purpose, are excluded. Please contact your
Pangbourne Castrol expert for any trials, discussions and all conversions.
Reading
RG8 7QR Castrol and the Castrol logo are trademarks of Castrol Limited, used under licence.
www.castrol.com/windenergy Castrol part of the BP group

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